3D Powder Modeling with Surface-Dense Binder Distribution
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Solution Overview
Problem
Existing 3D modeling methods face challenges in achieving accurate and strong 3D modeled objects due to uneven distribution of modeling solutions, leading to accuracy and strength issues.
Innovation Solution
A method involving the application of a modeling solution to powder laid in layers, where the density inside the 3D modeled object is smaller than on its surface, with alternating application areas to reduce seepage and enhance structural integrity, using a 3D modeling apparatus with liquid ejection units and powder management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the modeling solution is applied uniformly throughout the 3D modeled object, then the powder is evenly hardened, but the modeling solution seeps out from the object causing accuracy degradation and strength reduction
Solution Approach 1:
The patent applies different densities of modeling solution to different regions of the 3D modeled object. Specifically, the inside region receives a modeling solution with a lower density (fewer droplets per unit area) compared to the surface region, which receives a higher density. This local differentiation prevents excessive solution accumulation and seepage from the inside, thereby maintaining modeling accuracy while still achieving sufficient hardening of the powder throughout the structure.
2Strength
If the modeling solution density inside the object is increased to reduce empty spaces, then structural integrity improves, but solution seepage increases reducing accuracy
Solution Approach 1:
The patent implements local quality by establishing a density gradient of the modeling solution throughout the object. The inside region is treated with a lower density solution to prevent seepage and maintain accuracy, while the surface region receives a higher density solution to ensure complete powder hardening and structural integrity. This spatially varying approach allows the object to achieve both strength and precision simultaneously.
3Reliability
If the modeling solution is applied to all areas with high density, then complete powder hardening is achieved, but the object develops internal weaknesses and inaccuracy
Solution Approach 1:
The patent applies local quality principles by differentiating the modeling solution application between inside and surface regions. The surface region receives high-density solution application to ensure complete powder hardening and reliability, while the inside region receives lower-density application to prevent solution accumulation that would create internal weaknesses. This differentiated approach ensures both complete hardening where needed and internal structural strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the creation of 3D modeled objects with improved accuracy and strength by controlling the distribution of the modeling solution, reducing seepage and empty spaces, and maintaining structural integrity.
Implementation Method 1
applying a modeling solution to powder laid in layers, hardening the powder to which the modeling solution applied to form modeling layers
Implementation Method 2
immersing the 3D modeled object modeled at the modeling in a removal solution to remove the powder to which the modeling solution is not applied
Data Source
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AI summary
A method of manufacturing a 3D modeled object includes modeling including applying a modeling solution (10) to powder (20) laid in layers, hardening the powder (20) to which the modeling solution (10) applied to form modeling layers (30), and sequentially stacking the modeling layers (30) to form a 3D modeled object; and immersing the 3D modeled object modeled at the modeling in a removal solution to remove the powder (20) to which the modeling solution (10) is not applied. At the modeling, the modeling solution (10) is applied such that a density of the modeling solution (10) in an inside (124) of the 3D modeled object is smaller than a density of the modeling solution (10) in a surface (123) of the 3D modeled object and an area of the powder (20) to which the modeling solution (10) is applied and an area of the powder (20) to which the modeling solution (10) is not applied are alternate in the inside of the 3D modeled object.